Module frames

ABSTRACT

The method of making frames and frame units for modules of modular buildings includes steps of punching perimeter beams to form stops on the beams where cross-beams are to be located, and assembling the cross-beams with a pair of the perimeter beams by butting the ends of the cross-beams against corresponding stops to position the cross-beams without using jigs or fixtures to establish their positions. Retainers may be formed in the perimeter beams next to the stops to temporarily retain the cross-beams in place until they are welded to the perimter beams. In some frame units, the perimeter beams and cross-beams are metal channels, and the beams are assembled flange-to-flange and web-to-web. One weld is made to connect each abutting pair of flanges next to the webs, and another weld is made at a point separated farther from the webs so that the webs reinforce each other and the flanges reinforce each other. Cross-beams may also be welded to the stops on the perimeter beams. The invention includes the frame units, part of the strength and load handling capabilities of which are derived from particular arrangements of stops and welds.

United States Patent 1 Brown et a1.

[11] 3,717,964 W Feb. 27, 1973 MODULE FRAMES [73] Assignee: Behring Corporation, Ft. Lauderdale, Fla.

22 Filed: July 9,1970

21 Appl.No.:53,502

[52] US. Cl. ..52/79, 52/664, 52/690, 52/236 [51] Int. Cl. ..E04b l/34 [58] Field of Search ..52/715, 664, 666, 690, 696, 52/650, 663, 633, 236; 182/228; 287/189.36 13; 29/513, 469,155, 429; 219/107 [56] References Cited UNITED STATES PATENTS 1,133,138 3/1915 Henderson ..52/241 FOREIGN PATENTS OR APPLICATIONS 966,578 8/1957 Gen'nany ..52/656 694,018 6/1930 France ...l82/228 1,01 1,917 4/1965 Great Britain ..52/79 Primary Examiner-John E. Murtagh Assistant Examiner-l-Ienry E. Raduazo Attorney-Settle and Oltman [57] 1 ABSTRACT The method of making frames and frame units for modules of modular buildings includes steps of punching perimeter beams to form stops on the beams where cross-beams are to be located, and assembling the cross-beams with a pair of the perimeter beams by butting the ends of the cross-beams against corresponding stops to position the cross-beams without using jigs or fixtures to establish their positions. Retainers may be formed in the perimeter beams next to the stops to temporarily retain the cross-beams in place until they are welded to the perimter beams. In some frame units, the perimeter beams and crossbeams are metal channels, and the beams are assembled flange-to-flange and web-to-web. One weld is made to connect each abutting pair of flanges next to the webs, and another weld is made at a. point separated farther from the webs so that the webs reinforce each other and the flanges reinforce each other. Cross-beams may also be welded to the stops on the perimeter beams. The invention includes the frame units, part of the stren th and load handling capabilities of which are derive from particular arrangements of stops and welds.

SClaims, 18 Drawing Figures INVENTORS VICTOR E. BROWN RAUL. L. MORA EVANS T. MORTON BY SETTLE & OLI TMAN ATTORNEYS PATENTEDFEBZYIW 3117,96 1

SHEET 38F 4 INVENTORS VICTOR E. BROWN RAUL L. MORA EVANS T. MORTON 13 36 BY SETTLE & OLTMAN ATTORNEYS PATENTED FEB27 I973 SHEET U 0F 4 N A W W W o m m 5 RRO BOM no Am v EM E T L 1. R T mLN Uv A S [AV I6 vRE Y B F AT TORN EYS MODULE FRAMES BACKGROUND OF THE INVENTION i One particular type of modular building has modules which include metal frames made with beams and various other parts for doors, windows, wiring, plumbing, etc. Preferably, frame units for walls, floors and ceilings are constructed separately, and are then assembled in an assembly line and secured together to form a module. The positioning and retention of beams in constructing such frame units can result in large dimensional variations from unit to unit unless jigs and fixtures are used to accurately locate the beams. Howi ever, a manufacturer of modular homes ordinarily wishes to supply several different models of a given type of home, and due to design variations from one home model to another, different jigs and fixtures would be required for. each model. This complicates production as well as requiring substantial investment in jigs and fixtures.

SUMMARY OF THE INVENTION The present invention provides a method of making frames for modules wherein positioning of certain beams is accomplished in a self-jigging manner. Stops are provided on perimeter beams where cross-beams are to be located. This may be done by sequential punching in a programmed punch press to allow easy variation in the location of stops from one beam to another. Cross-beams are placed between two perimeter beams against corresponding stops. In some beams, retainers cooperate with the stops to temporarily hold the cross-beams. Then the cross-beams are welded to the perimeter beams to form frame units. Ultimately these frame units are assembled to form complete frames for modules and are welded together.

. The frame units and frames are part of the invention and derive part of their effectiveness from particular arrangements of stops and welds. Cross-beams may be welded to the stops on the perimeter beams, and this helps to unitize the frame units so that when loads are applied they are well distributed. Perimeter beams and cross-beams in floor and ceiling units are channels which are welded together flange-to-flange and web-toweb so that the webs reinforce each other and the flanges reinforce each other. This helps to prevent web crippling even when relatively thin gauge materials are used.

Accordingly, it is an object of the invention to provide a method ofmaking module frames which method is at least partly self-jigging.

Another object of the invention is to facilitate variation in beam locations from one module frame to another.

A further object of the invention is to construct a frame unit for a module so that it will distribute loads effectively.

Another object of the invention is to strengthen frames for modules by particular arrangements of welds.

Other objects of this invention will appear from the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate correspondingparts in the several views.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a module for a modular home;

FIG.- 2 is a perspective view of a frame for the module of FIG. 1, the frame not being completed with door openings, window openings and the like;

FIG. 3 is a sectional view taken along line 3-3 of FIG. 2 and looking in the direction of the arrows;

FIG. 4 is a sectional view taken along line 44 of FIG. 2 and looking in the direction of the arrows;

FIG. 5 is a sectionalview taken along line 5-5 of FIG. 2 and looking in the direction of the arrows;

FIG. 6 is a fragmentary perspective view of one cross-beam member extending between two perimeter beams in a wall frame unit included in the frame of FIG. 2;

FIG. 7' is a fragmentary sectional view taken along line 77 of FIG. 6;

FIG. 8 is a fragmentary perspective view of a portion of a perimeter beam for a floor frame unit or a ceiling frame unit;

FIG. 9 is a schematic view of a punch press useful in performing a punching operation in carrying out the method of the invention;

7 FIG. 10 illustrates a step of assembling cross-beams between two perimeter beams and placing the crossbeams against stops on the perimeter beams;

FIG. 11 further illustrates the placing of the crossbeams against stops on the perimeter beams;

FIG. 12 is a fragmentary perspective view illustrating FIG. 13 is an elevational view of two wall frame units stacked vertically as may be done in constructing multistory buildings;

FIG. 14 is a sectional view taken along line l4l4 of FIG. 13;

. FIG. 15 is a perspective view of a floor frame unit or ceiling frame unit as the case may be;

FIG. 16 is a sectional view takenalong line 16-16 of FIG. 15;

FIG. 17 is a fragmentary perspective view of a portion of the floor frame unit before assembly thereof showing in particular the assembling of a cross-beam with a perimeter beam; and

FIG. 18 is a fragmentary perspective view illustrating the step of welding the cross-beam and the perimeter beam together as well as showing the final arrangement of stops and welds.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways.

Also, it is to be understood that the phraseology or ter-- tion. A module 20 is shown in FIG. 1 to illustrate a typical module for one type of home, but it is to be understood that the invention is not limited in application to this particular module.

A basic frame structure 22 for a module such as the module 20 is shown in FIG. 2. It is to be understood that this frame structure illustrates the invention, but it is incomplete in that doors, windows, interior walls, and many other accessory structures have been omitted. The frame 22 includes a floor frame unit 24 and a roof frame unit 26. There are three wall frame units 28, 30 and 32'.

The wall frame unit 28 consists basically of two perimeter beams 34 and 36 which are each in the form of an angle beam, anda plurality of cross-beams 38 extending parallel to each other between the perimeter beams 34, 36. The cross-beams 38, known as studs, are preferably in the form of channel beams, as may be seen more clearly for example in FIG. 6. t

On the other side of'the frame 22, the wall frame unit 30 consists of two perimeter beams 40 and 42, each in the form of an angle beam, and a plurality of crossbeams 44 extending parallel to each other between the perimeter beams 40, 42. The cross-beams 44, known as studs, are channels identical to the channels '38. The other wall 32 likewise has two perimeter beams and cross-beams and is of the same construction as walls 28 and 30. The fourth wall has been omitted from FIG. 2 but is the same.

The floor frame unit 24 includes two perimeter beams 46 and 48, which are in the form of channels, and cross-beams or joists 50 which are also in the form of channels. The cross-beams 50 extend parallel to each other between the perimeter beams 46 and 48.

There may also be perimeter beams at the ends of the floor frame unit 24 such as the perimeter beam 52.

The roof or ceiling frame unit 26 is substantially identical to the floor frame unit 24 and includes perimeter beams 54 and 56 in the form of channels, and cross-beams. or joists 58 also in the form of channels. There may be perimeter beams at the ends of the frame unit 26 such as the perimeter beam 60.

All of the beams described and illustrated in connection with. FIG. 2 are made of metal, preferably high strength steel. It may be noted that the floor frame unit 24 and the roof or ceiling frame unit 26 are recessed within the wall frame units 28, 30 and 32. The perimeter beams 34 and 36 together with the studs 38 are welded to the perimeter beams 54 and 46. Similarly, the perimeter beams 40 'and 42 together with the studs 44 are welded to the perimeter beams 56 and 48. By having the floor frame unit 24 and the roof frameunit 26 welded to the inside faces of the wall frame units 28, 30 and 32, additional rigidity and strength is obtained tion at the welded joints. This feature of the frame construction is described and claimed in a co-pending application Ser. No. 38,100 filed on May I8, 1970 by John M. Evans and Evans T. Morton and assigned to the present assignee.

In accordance with one aspect of the present invention, the perimeter beams of the various frame units are provided with stops which may be in the form of tabs,

and the cross-beams which extend between the perimeter beams butt against these steps. Referring first to v in the final structure because there is less hinging ac- FIG. 3, it may be seen that the cross-beam 44 of the wall frame unit 32 butts against a stop or tab 62 formed in the perimeter beam 40. The lower end of cross-beam 44 likewise butts against an identical stop formed in the lower perimeter beam 42. In the roof frame 26, the end of a cross-beam 58 shown in FIG. 3 butts against two stops or tabs 64 and 66 formed in the perimeter beam 56. The same elements are shown in FIG. 4 from a different angle.

FIG. 5 is a sectional view taken through the other wall frame unit 28, and shows a cross-beam 38 having its upper end butting against a stop or tab 68 formed in the perimeter beam 34 and having its lower end butting against a stop or tab 70 formed in the perimeter beam 36. FIG. 5 also shows the left ends of two cross-beams 50 and 58. It may be seen that the end of cross-beam 58 butts against two stops or tabs 72 and 74 formed in the perimeter beam 54 of the roof frame unit. Similarly, the end of cross-beam 50 butts against two stops or tabs 76 and 78 formed in the perimeter beam 46 of the floor frame unit.

FIG. 6 illustrates how the cross-beams or studs of the 'wall frame units 28, 30 and 32 may be welded to the perimeter beams. In FIG. 6, the perimeter beams 34 and 36 are shown together with a cross-beam 38. It may be seen that there is a spot weld 80 between a flange of stud 38 and the inside flange of perimeter beam 34. There is another weld 82 connecting the web of stud 38 to the stop or tab 68. Likewise, at the lower end of stud 38 a weld 84 connects the inside flange of stud 38 to the inside flange of perimeter beam 36, and another spot weld 86 connects the web of stud 38 to the stop or tab 70. It is not essential to provide two welds at each end of the studs 38. For example, the welds 80 and 84 could be used alone or the welds 82 and 86 could be used alone.

FIGS. 6 and 7 illustrate retainer prongs 88 and 90 formed in the perimeter beam 34 directly adjacent the tab 68. It will be understood that there are identical prongs formed in the perimeter beam 36 directly adjacent and on opposite sides of the tab 70. As may be seen in FIG. 7, the web of the stud 38 fits between the prongs 88 and 90 and the tab 68. The studs can be forced over the prongs such as 88 and 90 when the studs are being placed against the stops such as stops 68. The prongs will yield to allow the end of the stud to pass and then spring back to retain the stud against the tab 68 until the stud is welded in place. This considerably simplifies the positioning of the studs, and saves a great deal of equipment which would otherwise be required for clamping and holding the studs in place.

FIG. 8 merely illustrates in greater perspective the configuration of the tabs 76 and 78 in the perimeter beam 50.

FIGS. 9 through 12 illustrate basic steps in the method of the invention. The invention includes a step of providing perimeter beams with stops located at predetermined positions spaced along the length thereof at which cross-beams are to be located. FIG. 9 illustrates how this may be accomplished. A perimeter beam 34 is shown passing through a punch press 91 which sequentially punches stops or tabs in the perimeter beam 34. The press 91 has die sets 92 and 94 which are designed to form both the tabs 68 and the retainer prongs 88,90 in a single punching step; The specific position of a given tab 68 and retainer 88,90 on the perimeter beam 34 can be controlled very accurately. The press 91 may be of the numerically controlled type. Thus, the locations of all of the tabs 68 for a given beam can be programmed into the press, and specific locations can be selected by feeding input information into the press such as from punched cards. Then as the beam 34 passes through the press, tabs 68 and retainer prongs 88 are punched at precisely located position where cross-beams are to be placed in the ultimate frame unit. It is easy to vary the spacing from one tab to another within a given beam merely by proper selection of the input information for the punch press. It is also easy to change the location of tabs from one beam to another.

It may be seen that by forming the stops on the perimeter beams at preselected positions on the beams as by a punching operation, a considerable investment in jigs and fixtures is saved. If it were necessary to rely upon jigs and fixtures to position the cross-beams, different fixtures would have to be provided for different positions of beams. The setup time for a given frame unit would be considerably increased, and there would be considerably more labor involved also.

FIGS. and 11 illustrate the step of assembling the cross-beams 38 with two perimeter beams 34 and 36 and placing the ends of the cross-beams 38 against the stops or tabs 68 and 70 to position the cross-beams without requiring jigs or fixtures to establish those positions. The beams 38 (and 44) are assembled vertically. FIG. 11 in particular shows the upper end of a crossbeam 38 being forced over the prongs 88 into position against a tab 68. FIG. 12 illustrates the lower end of the cross-beam 38 after it has been butted against the tab 70, and after the retainer prongs have returned to hold thelower end of the stud 38 in place.

FIG. 12 also shows the welds 86 and 84 which may perimeter beams. All of the wall frame units are made by essentially the same sequence of steps.

The floor frame unit 24 and the roof frame unit 26 are made by the sequential steps illustrated in FIGS. 15 through 18. A floor frame unit 24 is shown in FIG. 15 including the perimeter beams 46,48 and the crossbeams or joists 50. FIG. 16 shows the manner in which the joists 50 fit inside the channel flanges of the perimeter beams 46 and 48.

The first step is to punch the perimeter beams 46 and 48 to form the stops where cross-beams are to be located. Retainer prongs may be formed in the perimeter beams 46 and 48 if desired, but they are not necessary in all cases since the floor frame units are usually fabricated in a horizontal position. In FIG. 17, a single stop or tab 77 replaces the two stops 76 and 78 shown for example in FIG. 8. A retainer prong 100 is also shown. The stops 77 are punched at precise locations for cross-beams in exactly the same manner described in connection with FIG. 9. Then a plurality of the crossbeams 50 are assembled with the perimeter beams extending parallel between the perimeter beams. The ends of the cross-beams are placed against the stops 77 to position the cross-beams without requiring jigsor fixtures for their positioning. Next, the cross-beams are welded to the perimeter beams.

A specific arrangement of welds which is unexpectedly strong is shown in FIG. 18. It may be seen that the web 1020f beam 50 is welded to the tab 77 at 104 and 106. The tab 77 is perpendicular to the flanges 108 and 110, and the tab 77 thusprovides a corner at 112 which stiffens the web 114 of beam 46. By having the tab 77 welded to the web 102, the two webs 114 and 102 reinforce each other.

Also, the flange 108 is welded to flange 116 and flange is welded to flange 118 in a desirable manner. There are welds at 120 and 122 which are very close to the two webs 102 and 114, these welds being very close to the comer formed by the two webs 102 and 114. There are two other welds 124 and 126 separated farther from the webs 102 and 114 than the welds 120 and 122, and these welds are spaced diagonally from welds 120 and 122.

Thus, welds 120 and 122 effectively weld the two beams together web-to-web, and the two welds 124 and 126 effectively weld the two beams 50 and 46 together flange-to-flange. This means that the webs 102 and 114 reinforce each other and the flanges 116 and 118 respectively reinforce the flanges 108 and 110.

After the frame units have all been assembled and welded, the various frame units 24, 26, 28, 30 and 32 areassembled together into a generally cubicle shape and are welded together in accordance with the previous description. The frame units are ordinarily finished with surfacing material and other structure before they are welded together. In a commercial production facility, the frame units may be completed in subasscmbly bays, and then assembled together and welded on a final production line. FIG. 18 shows that the crossbeams 50 of the floor frame unit 24 may be filled or relatively low frequency which does not have unpleasant qualities. I

As previously mentioned, the particular arrangement of welds shown in FIG. 18 gives unexpected strength to the floor and roof frame units 24 and 26. The webs of the various beams reinforce each other and the flanges of these beams also reinforce each other. As a result, it is possible to use relatively thin gauge material for the beams and still achieve frame units of high compressive and tensile strength. Similarly, the welding of the crossbeams or studs 38 and 44 in the wall frame unit to the tabs or stops such as the tabs 68 and 86 shown in FIGS. 11 and 12 increases the strength and load distributing characteristics of the wall frame unit. This is illustrated particularly in FIGS. 13 and 14. In FIG. 13, two wall frame units 28 and 28' are shown stacked one above the other as they would be arranged if two frames 22 were placed one above the other. This happens in construction of multi-story buildings. It may be seen that if some of the studs 38 and 38' were shorter than others, there would be a possibility of the perimeter beams 34 and 36 becoming distorted with a resultant uneven distribution of loads. However by welding the studs 38 132 between the perimeter beams 34 and 36' as shown in FIG. 14. The styrofoam will compress to conform to the beams 34 and 36' and thus take up any irregularities in these beams.

It is apparent that the invention provides module frames and a method of making module frames wherein certain positioning steps are self-jigging. This considerably speeds up production, reduces investment in jigs and fixtures, saves labor and conserves floor space in an assembly operation. Furthermore, the welding of the various beams to the stops which are used for selfjigging imparts strength to the structures and improves load distribution. A particular arrangement of welds is provided for the floor and roof frame units which imparts unexpectedly high strength to these structures. The floor frame unit can be sound deadened in an extremely simple manner.

Having thus described our invention, we claim:

1. A frame unit for a module of a modular building including in combination, a pair of metal perimeter beams in the form of channels which are parallel to each other and spaced apart by a cross-dimension of a frame unit, each of said perimeter beams having a plurality of tabs punched out from and integral with the channel web thereof and projecting between the channel flanges, said tabs being spaced all along the length of said perimeter beams and located at predetermined positions for cross-beams, a plurality of cross-beams in the form of channels spaced all along and extending between said perimeter beams parallel to each other and having ends butting against respective ones of said tabs to position the same, each of said cross-beams having the channel flanges thereof respectively abutting the channel flanges of said perimeter beams and the web thereof abutting the webs of said perimeter beams to form corners, and each abutting pair of flanges having a first spot weld joining the same at a comer next to the webs of said beams and a second spot weld joining the same at a point spaced diagonally along said pair of flanges from said corner so that the webs of said perimeter beams and said cross-beams reinforce each other and the flanges of said perimeter beams and said cross-beams reinforce each other.

2. The frame unit as claimed in claim 1 in which the webs of said cross-beams are spot welded to said tabs.

3. A frame unit for a module of a modular building including in combination, a pair of angled metal perimeter beams which are parallel to each other and spaced apart by a cross-dimension of a frame unit, said perimeter beams having a web and at least one flange, each of said perimeter beams having a plurality of tabs integral therewith and projecting along a flange thereof, said tabs being spaced at intervals all along the length of said perimeter beams to provide stops for positioning cross-beams, a plurality of angled metal cross-beams spaced all along and extending between said perimeter beams parallel to each other, said crossbeams having a web and at least one flange, each of said cross-beams having the web thereof abutting a pair of said tabs on said perimeter beams and forming a corner with the webs of the perimeter beams, each cross-beam also having at least one flange thereof respectively fitting inside and abutting the flanges of said perimeter beams, and each abutting pair of flanges having a first spot weld interconnecting the same at a corner next to the webs of said beams and a second spot weld spaced diagonally along said pair of flanges from said first spot weld and separated farther than said first weld from the webs of said beams so that the webs of said perimeter beams and said cross-beams reinforce each other and the flanges of said perimeter beams and said cross-beams reinforce each other. 

1. A frame unit for a module of a modular building including in combination, a pair of metal perimeter beams in the form of channels which are parallel to each other and spaced apart by a cross-dimension of a frame unit, each of said perimeter beams having a plurality of tabs punched out from and integral with the channel web thereof and projecting between the channel flanges, said tabs being spaced all along the length of said perimeter beams and located at predetermined positions for cross-beams, a plurality of cross-beams in the form of channels spaced all along and extending between said perimeter beams parallel to each other and having ends butting against respective ones of said tabs to position the same, each of said cross-beams having the channel flanges thereof respectively abutting the channel flanges of said perimeter beams and the web thereof abutting the webs of said perimeter beams to form corners, and each abutting pair of flanges having a first spot weld joining the same at a corner next to the webs of said beams and a second spot weld joining the same at a point spaced diagonally along said pair of flanges from said corner so that the webs of said perimeter beams and said cross-beams reinforce each other and the flanges of Said perimeter beams and said cross-beams reinforce each other.
 2. The frame unit as claimed in claim 1 in which the webs of said cross-beams are spot welded to said tabs.
 3. A frame unit for a module of a modular building including in combination, a pair of angled metal perimeter beams which are parallel to each other and spaced apart by a cross-dimension of a frame unit, said perimeter beams having a web and at least one flange, each of said perimeter beams having a plurality of tabs integral therewith and projecting along a flange thereof, said tabs being spaced at intervals all along the length of said perimeter beams to provide stops for positioning cross-beams, a plurality of angled metal cross-beams spaced all along and extending between said perimeter beams parallel to each other, said cross-beams having a web and at least one flange, each of said cross-beams having the web thereof abutting a pair of said tabs on said perimeter beams and forming a corner with the webs of the perimeter beams, each cross-beam also having at least one flange thereof respectively fitting inside and abutting the flanges of said perimeter beams, and each abutting pair of flanges having a first spot weld interconnecting the same at a corner next to the webs of said beams and a second spot weld spaced diagonally along said pair of flanges from said first spot weld and separated farther than said first weld from the webs of said beams so that the webs of said perimeter beams and said cross-beams reinforce each other and the flanges of said perimeter beams and said cross-beams reinforce each other.
 4. The frame unit as claimed in claim 3 in which the ends of said cross-beams and said tabs have a spot weld connecting them together.
 5. A box module for a modular building consisting of a plurality of frame units as claimed in claim 3 having the perimeter beams thereof welded together at corners to form the box module, the frame units including horizontal ceiling and floor frame units and a plurality of vertical side frame units. 